Sealant dispenser and control method thereof

ABSTRACT

A dispenser includes a light emitter to emit a light beam toward a surface of a substrate, a light receiver to receive the light beam reflected from the substrate, and a coupling hole, between the emitter and receiver, to receive a lower section of a syringe. The emitter, receiver, and coupling hole may be provided in a single support structure, and the coupling hole is located between a light emitting plane of the emitter and a light receiving plane of the receiver.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/118,278, filed on May 9, 2008, which is a continuation of U.S. Pat.No. 7,540,924, filed on May 10, 2005. The contents of both documents areincorporated herein by reference.

BACKGROUND

1. Field

One or more embodiments disclosed herein relate to apparatuses andmethods for applying a material such as a sealant onto a substrate.

2. Background

In general, liquid crystal display (LCD) is lighter and smaller byvolume than a traditional image display device using cathode-ray tube(CRT). Therefore, making great strides in recent years, LCD has beenwidely applied in many display devices, such as computer monitors andTVs.

In case of the LCD, there is a certain space between an upper substrateand a lower substrate, and the space is filled with liquid crystal. Inorder for the LCD to perform its operation at optimum state, a cell gapof the lower and upper substrates should be maintained uniformly. Inaddition, in order to prevent excessive liquid crystal dispensing orinsufficient filling of the space, it is very important to have a goodpositioning precision of a sealant coating for sealing the upper andlower substrates, and a proper control on the amount of coating beingsupplied to the substrates. This is because if the cell gap is notuniform or if liquid crystal is applied too much or insufficiently, thescreen uniformity over the entire screen of an LCD will be deteriorated.

A sealant used to seal the space between the lower and the uppersubstrate not only maintains a uniform cell gap, but also seals theupper and the lower substrate.

A sealant is applied to a substrate by means of a sealant dispenser. Thesealant dispenser includes a stage on which the substrate is mounted,and a head unit provided with a nozzle for discharging the sealant.

Here, the nozzle makes a relation motion to the substrate, and applies asealant of a designated shape onto the substrate. In other words, thenozzle moves into X-axis and Y-axis directions relatively to thesubstrate, and applies the sealant onto the substrate. Also, the nozzleis movable into Z-axis direction to adjust its height with respect tothe substrate.

FIG. 1 illustrates a head unit of a related art sealant dispenser. Ascan be seen in the drawing, the head unit of the sealant dispenserincludes a syringe 20 for storing a sealant, and a nozzle 32 coupled toa lower portion of the syringe 20, for discharging the sealant 50.

A long bar-shaped bracket 30 is connected to the syringe 20 in ahorizontal direction, and the nozzle is installed on the end of thebracket 30. And, a distance sensor 40 for measuring a vertical distancebetween the nozzle 32 and the substrate 10 is installed in the vicinityof the nozzle 32.

More specifically, the distance sensor 40 is spaced apart apredetermined distance (L) from the syringe 20 which is filled with thesealant. Here, the syringe 20 and the distance sensor 40 must beinstalled in parallel because of their own volumes. Therefore, in orderto put the nozzle communicated with the syringe as close as possible tothe focal point of the distance sensor, the syringe and the nozzle mustbe installed in ‘L’ shape.

Usually, an optical laser distance sensor is used for the distancesensor 40. The bottom surface of the distance sensor has a “ ”, where alight emitting part 42 for emitting a laser beam 46 is installed on oneside and a light receiving part 44 for receiving a laser beam 46 is onthe other side.

Here, the light emitting part 42 emits a laser beam 46 towards thesubstrate, whereas the light receiving part 44 receives the laser beamreflected from the substrate. As such, the distance sensor 40 measures adistance between the substrate 10 and the nozzle 32.

When the laser beam path is changed due to a flexure on thesealant-applied surface of the substrate 10, the distance sensormeasures the laser beam received to the light receiving part andtransfers its measured value to a controller (not shown).

However, the related art sealant dispenser has the following problems.

Firstly, since the nozzle and the syringe are spaced a designateddistance apart, the flow path of the sealant is bent in “L” shape. Indetail, the distance sensor and the syringe of the related sealantdispenser are separately installed in the head unit while maintaining adesignated distance from each other. This is why the flow path of thesealant has an “L” shape.

In that light, the related art dispenser requires a high pressure fordischarging the sealant, and the usage of a highly viscous sealant waslimited.

Secondly, according to the related art sealant dispenser, the nozzle isinstalled on the lower portion of the bracket, so that there is a greatdistance between the position on the substrate where the sealant isdischarged and the position on the substrate where a laser beam isreflected. Therefore, the distance sensor cannot get an accurate avertical distance from the point to which the sealant is actuallydischarged to the nozzle.

Thirdly, since the flow path of the sealant in the related art sealantdispenser is in “L” shape, the sealant is relatively slowly discharged.Hence, it is not clear exactly where sealant dispensing starts and ends.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to a lighting opticalsystem that substantially obviates one or more problems due tolimitations and disadvantages of the related art.

An object of the present invention is to provide a sealant dispenserfeaturing a low pressure for dispensing the sealant, and a controlmethod thereof.

Another object of the present invention is to provide a high precisionsealant dispenser and a control method thereof.

Still another object of the present invention is to provide a sealantdispenser featuring an accurate control over the dispensing position anddispensing amount of a sealant by increasing the response speed of asealant to be dispensed, and a control method thereof.

Additional advantages, objects, and features of the invention will beset forth in part in the description which follows and in part willbecome apparent to those having ordinary skill in the art uponexamination of the following or may be learned from practice of theinvention. The objectives and other advantages of the invention may berealized and attained by the structure particularly pointed out in thewritten description and claims hereof as well as the appended drawings.

To achieve these objects and other advantages and in accordance with thepurpose of the invention, as embodied and broadly described herein,there is provided a sealant dispenser, including: a stage on which asubstrate is mounted; a nozzle for dispensing a sealant while making arelative motion with the substrate; a syringe coupled to the nozzle, forstoring the sealant; and a distance sensor installed on both sides of alower portion of the syringe, for measuring a vertical distance betweena principal plane of the substrate and an outlet of the nozzle.

Preferably, the distance sensor includes: a light emitting part foremitting a laser beam towards the substrate; a light receiving part forreceiving a laser beam reflected from the substrate; and a sensorsupporting part for supporting the light emitting part and the lightreceiving part.

Preferably, the sensor supporting part includes a coupling hole that thenozzle passes through.

More preferably, the coupling hole is disposed between the lightemitting part and the light receiving part.

Preferably, the syringe and the outlet of the nozzle have substantiallythe same central axis.

More preferably, a focal point of a laser beam emitted form the distancesensor, the nozzle, and the syringe are arranged on the same axis.

Preferably, the light emitting part and the light receiving part of thedistance sensor are aligned in a straight line along the principal planeof the substrate, and the light emitting part and the light receivingpart are combined as one body.

Preferably, the vertical distance between the substrate and the nozzleis maintained at a constant value.

Another aspect of the present invention provides a sealant dispenser,including: a stage on which a substrate is mounted; a nozzle fordispensing a sealant while making a relative motion with the substrate;a distance sensor for measuring a vertical distance between a principalplane of the substrate and an outlet of the nozzle; and a positiondetecting sensor for detecting a horizontal position of the nozzle onthe principal surface of the substrate.

Preferably, the position detecting sensor and the nozzle are locatedeach other at the opposite sides with respect to the substrate.

Preferably, the sealant dispenser further includes an adjusting part foradjusting the position of a syringe storing the sealant.

Preferably, a measuring point on the principal plane of the substrate inwhich a laser beam from the distance sensor is reflected is disposed ona front end of the nozzle along the direction of the sealantapplication.

More preferably, the nozzle and the measuring point maintain a minimumdistance from each other so that the laser beam does not interfere withthe sealant.

Still another aspect of the present invention provides a control methodof a sealant dispenser, which the method includes the steps of: in aposition detecting sensor installed below a substrate, setting ahorizontal position of a nozzle on a principal plane of the substrate;in a distance sensor installed on both sides of a lower portion of asyringe, setting a vertical distance between the substrate and thenozzle; and dispensing a sealant to the position being set.

Preferably, the step for setting the horizontal position of the nozzleincludes the sub-step of: measuring a horizontal distance between ameasuring point on the substrate in which a laser beam is reflected andthe nozzle; and deciding whether the measured horizontal distance fallswithin a predetermined allowable range.

Preferably, the method further includes the step of: if the measuredhorizontal distance is outside the allowable range, revising thehorizontal position of the nozzle.

Preferably, the step for setting the vertical distance between thesubstrate and the nozzle includes the sub-steps of: measuring a verticaldistance between the substrate and the nozzle; and deciding whether themeasured vertical distance falls within a predetermined allowable range.

Preferably, the method further includes the step of: if the measuredvertical distance is outside the allowable range, revising the verticaldistance between the nozzle and the substrate.

Preferably, the vertical distance between the substrate and the nozzleis revised to maintain a constant value.

Preferably, the syringe and the nozzle for dispensing the sealant to theprincipal plane of the substrate have substantially the same centralaxis.

It is to be understood that both the foregoing general description andthe following detailed description of the present invention areexemplary and explanatory and are intended to provide furtherexplanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this application, illustrate embodiment(s) of the invention andtogether with the description serve to explain the principle of theinvention. In the drawings:

FIG. 1 is a perspective view illustrating a head unit of a related artsealant dispenser;

FIG. 2 is a front view illustrating key elements of a sealant dispenseraccording to the present invention;

FIG. 3 is a side view of a key element taking in the direction of arrowA in FIG. 2;

FIG. 4 illustrates a detected position of a distance sensor photographedby a position detecting sensor, and a location of a nozzle; and

FIG. 5 is a flow chart explaining a control method of a sealantdispenser according to the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to the preferred embodiments of thepresent invention, examples of which are illustrated in the accompanyingdrawings.

FIG. 2 is a front view illustrating key elements of a sealant dispenseraccording to the present invention; FIG. 3 is a side view of a keyelement taking in the direction of arrow A in FIG. 2; and FIG. 4illustrates a detected position of a distance sensor which isphotographed by a position detecting sensor, and a location of a nozzle.

Referring to FIGS. 2 to 4, the sealant dispenser of the presentinvention includes a nozzle 130 for discharging a sealant while making arelative motion to a substrate 110 mounted on a stage, a syringe 120coupled to the nozzle 130, for storing the sealant, and a distancesensor 140 installed on both sides of the lower portion of the syringe120, for measuring a vertical distance from the principal plane of thesubstrate 110 to an outlet of the nozzle 130.

The syringe 120 for storing a sealant is in conical shape of which theinside diameter decreases in the downward direction, and is installedperpendicularly to the surface of the substrate 110. Also, the nozzle130 is coupled to one end of the syringe 120, and the outlet of thenozzle 130 is installed in such a manner to have substantially the samecentral axis with the syringe 120. As shown in FIG. 2, the syringe issupported by a syringe coupler 320.

The sealant 150 in the syringe 120 travels along a straight flow pathand is discharged from the nozzle. In result, the response speed of thesealant is increased according to a positive or negative pressure signalof a controller that controls the amount of the sealant to be applied,and the sealant can be applied to an accurate position on the substrate.Especially, since the start point and the end point of dispensing areset precisely, defect rate can be reduced markedly.

The distance sensor 140 includes a light emitting part 142 for emittinga laser beam toward the substrate 110, a light receiving part 144 forreceiving a reflected laser beam from the substrate 110, and a sensorsupporting part 145 for supporting the light emitting part 142 and thelight receiving part 144. As shown in FIG. 2, light emitted from thelight emitting party 142 is substantially perpendicular to a lightemitting plane 342. Light received by the light receiving part 144 issubstantially perpendicular to a light receiving plane 344.

The sensor supporting part 145 is installed above the light emittingpart 142 and the light receiving part 144, encompassing the lowerportion of the syringe 120. And, the sensor supporting part 145 isprovided with a coupling hole 148 between the light receiving part 144and the light emitting part 142, so that the nozzle 130 passing throughthe coupling hole 148 is located between the light receiving part 144and the light emitting part 142. As shown in FIG. 2, the coupling hole148 receives a lower part of the syringe 120.

Optionally, the sensor supporting part 145 can have a first sensorsupport supporting the light receiving part 144 and a second sensorsupport supporting the light emitting part 142. That is, the lightreceiving part 144 and the light emitting part 142 are separatelyinstalled on both sides of the lower portion of the syringe, and thelower portion of the syringe mounted with the nozzle is installedbetween the light receiving part 144 and the light emitting part 142.

Apart from the above constitutional elements, the present invention alsoincludes a head unit structure in which the focal point of a laser beamemitted form the distance sensor, the nozzle, and the syringe areserially arranged on the same axis.

As can be seen in FIG. 3, the light emitting part and the lightreceiving part of the distance sensor 140, and the syringe 120 arealigned in parallel to the principal surface of the substrate. Indetail, if seen in the direction of arrow A in FIG. 2, the distancesensor 140 is installed symmetrically around the center of the syringe.

Preferably, the light emitting part 142 and the light receiving part 144of the distance sensor 140 are combined as one body. However, this isfor illustrative purposes only and the present invention is not limitedthereto. As aforementioned, therefore, it is possible to install thelight transmitting part and the light receiving part separately fromeach other, and put the nozzle therebetween.

The distance sensor 140 measures a vertical distance between the nozzle130 and the substrate 110 to which the sealant 150 is applied. To thisend, the light emitting part 142 of the distance sensor 140 emits alaser beam towards the substrate 110, and the light receiving part 144receives a reflected laser beam from the substrate 110.

If the vertical distance between the substrate 110 and the nozzle 130 ischanged due to a flexure on the surface of the substrate 110, the heightfrom a point of laser beam reflection is changed. Consequently, not onlythe laser beam is received at a different position on the lightreceiving part 144, but also the phase of the laser beam is changed.Based on these changes, the distance sensor 140 measures the verticaldistance from the nozzle 130 and the substrate 110.

The measured vertical distance between the nozzle 130 and the substrate110 is sent to a controller (not shown). Then, the controller (notshown) moves the nozzle 130 and the substrate 110 relatively to eachother until the vertical distance has a predetermined value. Examples ofa driving means (not shown) for moving the substrate and the nozzleinclude a linear motor and a servomotor.

Meanwhile, as shown in FIG. 2, a measuring point 112 on the substrate110 from which a laser beam 146 is reflected is disposed a predetermineddistance away from a position where the sealant 150 is applied. If themeasuring point 112 and the position to which the sealant 150 is appliedare coincident, the distance sensor 140 is interfered with its distancemeasurement by the sealant 150 applied to the substrate 110. Thus, it isimportant that the measuring point 112 and the nozzle 130 are spacedapart at least at a minimum distance for the sealant not to interferewith the laser beam. Moreover, the measuring point 112 is preferablylocated on a front end of the nozzle, along the direction of the sealantapplication.

However, the above-described embodiments are merely exemplary and arenot to limit the present invention. In effect, the measuring point andthe position to which the sealant is applied can be located within apredetermined allowable range. Also, the measuring point can be locatedin any position close to the nozzle, along the direction of the sealantapplication.

Furthermore, a position detecting sensor 170 is installed below thesubstrate 110 and detects a horizontal distance between the nozzle 130and the measuring point in which the laser beam emitted from thedistance sensor 140 is reflected. Precisely speaking, the positiondetecting sensor 170 and the nozzle 130 are located at the oppositesides with respect to the substrate 110.

Although a camera is preferably used as the position detecting sensor170, any type of sensor capable of detecting the position of the nozzleand the measuring point can be utilized.

As depicted in FIG. 4, a screen 175 photographed by the positiondetecting sensor 170 displays the nozzle and the measuring point.

Since the substrate 110 coated with the sealant 150 is a transparentglass, the measuring point 112 and the nozzle 130 are projected onto thesubstrate 110. Hence, the position detecting sensor 170 regards aposition on the substrate 110 where the nozzle 130 is projected as aplace where the sealant 150 should be applied, and detects a distance dbetween the measuring point 112 and the nozzle 130.

If the distance d between the measuring point 112 and the nozzle 130 isoutside the predetermined allowable range, an adjusting part 160 mountedon the head unit adjusts the position of the syringe coupled to thenozzle.

Actually, the adjusting part 160 is connected to the syringe andminutely adjusts the coupling position of the syringe. The adjustingpart 160 includes a motor to be able to adjust the coupling position andangle of the syringe 120.

Alternatively, if the nozzle is stopped, a stage (not shown) supportingthe substrate can be driven to adjust the horizontal distance betweenthe nozzle and the substrate.

FIG. 5 is a flow chart explaining a control method of the sealantdispenser according to the present invention. The control method of thesealant dispenser will now be described in greater detail below.

As can be seen in FIG. 5, the control method of the sealant dispenser islargely divided into three steps: a first set-up step (S100) performedby the position detecting sensor, for setting or specifying a horizontalposition of the nozzle on the principal plane of the substrate; a secondset-up step (S200) performed by the distance sensor, for setting avertical distance between the substrate and the nozzle; and a sealantdispensing step (S300) for dispensing or applying a sealant to theposition set in the first and second steps.

In the first set-up step (S100), when the syringe descends, the nozzlecoupled to the syringe moves close to the surface of the substrate.Here, it is also acceptable for the nozzle to touch the surface of thesubstrate.

Then, the position detecting sensor installed below the substratephotographs the measuring point on the substrate in which the laser beamreflects and the position of the nozzle, to detect the horizontaldistance between the measuring point and the nozzle (S110).

Once the horizontal distance between the nozzle and the measuring pointis detected, it is decided whether the measured horizontal distance iswithin the predetermined allowable range (S130).

Here, the allowable range indicates a user-specified range for anappropriate distance between the measuring point and the nozzle.Preferably, the allowable range is set up differently, depending on akind of the sealant used and pressure/speed of dispensing the sealant.

If a result of the first decision in step S130 tells that the distancebetween the measuring point and the nozzle is within the allowablerange, the method proceeds to a second set-up step for setting thevertical distance between the nozzle and the substrates (S200).

On the other hand, if the horizontal distance between the measuringpoint and the nozzle is outside the allowable range, the position of thenozzle is revised (S150). In this revision step, the adjusting partmounted on the head unit revises the position of the syringe to makesure that the horizontal distance between the measuring point and thenozzle falls within the allowable range. After revising the position ofthe syringe, it is preferable to measure the horizontal distance betweenthe measuring point and the nozzle again.

When the first set-up step (S100) for setting the horizontal position ofthe nozzle on the surface of the substrate is over, the method proceedsto the second set-up step (S200) for setting the horizontal distancebetween the substrate and the nozzle.

In the second set-up step (S200), the distance sensor on thecircumference of the lower portion of the syringe measures the verticaldistance between the substrate and the nozzle (S210). Because theprocedure associated with the measurement of the vertical distance hasbeen already described referring to the constitutional elements of thedistance sensor, it will not be explained here.

Once the vertical distance is measured, it is decided as a seconddecision step whether the measured vertical distance falls within theallowable range (S230). If a result of the second decision tells thatthe vertical distance is within the allowable range, the sealant isdischarged (or dispensed) through the outlet of the nozzle (S300).

However, if a result of the second decision tells that the verticaldistance is outside the allowable range, the vertical distance betweenthe nozzle and the substrate is revised (S250).

In the revision step S250, either the syringe coupled to the nozzle canbe moved vertically with respect to the surface of the substrate, or theother way round (i.e., the substrate can be moved vertically withrespect to the nozzle). Either way, the vertical distance between thesubstrate and the nozzle must maintain a constant value.

When the vertical distance between the nozzle and the substrate fallswithin the allowable range through the revision, the sealant isdischarged (or dispensed) through the outlet of the nozzle (S300).During the sealant dispensing step (S300), the syringe and the nozzledispense the sealant while moving around substantially the same pivot.

The sealant dispenser and its control method have the followingadvantages.

Firstly, the syringe and the nozzle have substantially the same pivotaccording to the principles of the present invention, so that the flowpath of the sealant becomes a straight line, which in turn lowers thepressure required for discharging (or dispensing) the sealant. Thismeans that diverse kinds of sealants including a highly viscous sealantcan be utilized.

Secondly, the distance between the measuring point on the substrate inwhich the laser beam is reflected and the position to which the sealantis applied is minimized, so that the sealant can be applied moreprecisely.

Thirdly, since the flow path of the sealant is a straight line, theresponse speed of the sealant to be dispensed is increased. Thus, aprecise amount of the sealant can be applied to an accurate position.Especially, by setting the start point and the end point of dispensingmore precisely, the defect rate is reduced markedly.

Fourthly, by setting the distance between the nozzle and the distancesensor within the allowable range, the application of the sealant can becontrolled more precisely, and replacement of the syringe can be doneeasily and quickly.

The forgoing embodiments are merely exemplary and are not to beconstrued as limiting the present invention. The present teachings canbe readily applied to other types of apparatuses. The description of thepresent invention is intended to be illustrative, and not to limit thescope of the claims. Many alternatives, modifications, and variationswill be apparent to those skilled in the art.

1. A dispenser, comprising: a light emitter to emit a light beam towarda surface of a substrate; a light receiver to receive the light beamreflected from the substrate; and a coupling hole, between the emitterand receiver, to receive a lower section of a syringe, wherein theemitter, receiver, and coupling hole are provided in a single supportstructure, wherein a light emitting plane of the emitter and a lightreceiving plane of the receiver face each other in a slanted fashion,and wherein the coupling hole is located between the light emittingplane and the light receiving plane.
 2. The dispenser of claim 1,further comprising: a syringe coupler located above the coupling holeand between the emitter and receiver, wherein the syringe coupler has ahole through which the syringe passes that is wider than the couplinghole, so as to receive a tapered surface of the lower section of thesyringe.
 3. The dispenser of claim 2, wherein the syringe, syringecoupler, coupling hole, and a focal point of reflection of the lightbeam are located along substantially a same vertical axis.
 4. Thedispenser of claim 3, wherein the coupling hole passes through saidsingle support from a first location proximate the tapered surface ofthe lower section of the syringe to a second location proximate an upperportion of at least one of the light emitting plane or the lightreceiving plane.
 5. The dispenser of claim 1, further comprising: anozzle coupled to a distal end of the syringe, wherein a distancebetween the nozzle and substrate is determined based on the reflectedlight beam received by the light receiver.
 6. The dispenser of claim 5,further comprising: a controller to adjust a position of the nozzlebased on the distance measured between the nozzle and substrate.
 7. Thedispenser of claim 5, further comprising: a sensor located under thesubstrate, wherein the substrate is at least partially transparent toallow the sensor to detect a distance between a focal point ofreflection of the light beam on the substrate and a nozzle dispensing amaterial onto the substrate.
 8. The dispenser of claim 7, furthercomprising: a controller to adjust a position of the nozzle or syringebased on the distance measured between the focal point of reflection ofthe light beam and the nozzle.
 9. The dispenser of claim 5, wherein: thenozzle dispenses a sealant while moving relative to the substrate, thesyringe stores the sealant therein, the syringe and an outlet of thenozzle are aligned along substantially a same central axis, and theemitter and receiver are installed on different sides of the lowersection of the syringe.